CN1829599B - 涂覆碳化物丝锥 - Google Patents
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Abstract
一种涂覆碳化物丝锥(10)包含基体(16),所述基体(16)包括采用12-16重量%钴粘结的碳化钨,还添加少量过渡金属碳化物以限制晶粒长大,而且,还可以含有少量可能在处理期间溶入的杂质。基体(16)上涂覆有一个金属氮化物、碳化物、碳氮化物、硼化物和/或氧化物层,所述金属选自于一种或多种下述元素:铝、硅和周期表中的IVa,Va和VIa族过渡金属。所述涂层可以包括一个单层(56)和/或任选具有不同化学组成的交替层。为了降低摩擦,可以在所述涂层上作为单层共沉积,或者以多层或交替层形式沉积一个包含二硫化钼、二硫化钼和过渡金属或者它们的组合、碳、碳和过渡金属碳化物或者它们的组合和/或碳氮化物的外顶层。本发明的涂覆碳化物丝锥(10)可以在比传统丝锥至少快三倍的切削速度下使用而不会发生碎屑或破断。
Description
相关申请的相互说明
本申请与2002年10月9日提交、系列号为10/267,387、名称为“具有耐磨低摩擦涂层的工具及其制备方法”的美国专利申请有关,在此引入其全部内容作为参考。
发明背景
发明领域
本发明涉及切削刀具。更具体地,本发明涉及用于对钢及其他铁基合金进行攻丝的涂覆碳化物丝锥。
相关技术描述
众所周知,切削刀具产生的高温足于会限制刀具的寿命,因而降低了有用的切削速度。存在各种用来制造切削刀具的材料。切削刀具通常采用称作高速钢的一类工具钢制造。虽然高速钢具有优异的强度和韧性,但是,与更耐高温的材料相比,它们只具有较低的温度抗力。
烧结碳化钨由于具有较高的硬度和包括高切削温度下保持硬度能力在内的高温稳定性,因此,其比工具钢例如高速钢更适于制造切削刀具的材料。典型地,采用烧结碳化物制造的切削刀具可以在比由高速钢制造的刀具至少高出三倍的切削速度下使用,而且刀具的寿命更长。但是,烧结碳化钨的断裂韧性和强度均比高速钢低,这就限制其在某些机加工操作中使用。
一种用来产生内部螺纹线的加工操作叫做攻丝。目前存在两种攻丝方法。主要的攻丝方法是通过切削和去除孔壁的材料产生V形螺旋螺纹。或者,内部螺纹通过移动材料形成内部螺旋螺纹来产生。然而,成形丝锥比切削丝锥所需动力高的多,而且在螺纹的内径处产生不完美的螺纹顶部。为此,切削丝锥通常比成形丝锥更为优选。
与例如在车削、磨削、钻削和铰孔中使用的其他大部分切削刀具不同,攻丝工具的横截面较弱,另外其切削刃也较弱。为此,根据现有技术由烧结碳化物制造的丝锥仅仅具有非常有限的用途。当使用当前设计的碳化物丝锥时,即使对于相对容易加工的材料例如钢,切削刃也容易发生碎裂或破断,致使刀具无法使用。为此,现有技术的碳化物丝锥被限制用于对甚至比钢更容易切削的材料,例如铝和铸铁进行攻丝。钢和其它铁基合金是要求螺纹的装配件最常使用的材料。因此,如果切削刃发生碎裂和破断的问题得到克服,则由烧结碳化钨制造的丝锥将会比由高速钢制造的丝锥更具优势。
含有采用超过约3重量%的其他碳化物如碳化钽、碳化钛和碳化铌合金化的碳化钨的烧结碳化物当用作切削钢和其他铁基合金的工具材料时,具有很高的耐磨性。然而,这类碳化物强度和韧性不足,难以用作丝锥材料。或者,主要包含采用浓度超过10重量%的钴粘结的碳化钨的一类烧结碳化物强度高,但是在加工钢时其耐磨性低,因此,不适合作为攻丝钢的工具材料。
发明概述
简言之,根据本发明,提供由包含采用约12-16重量%钴粘结的碳化钨的工具材料制造并且采用金属氮化物、碳化物、碳氮化物、硼化物和/或氧化物涂覆的的丝锥,其中,所述金属选自于一种或多种下述元素:铝、硅和周期表中的IVa,Va,和VIa族过渡金属。
附图简述
由下面参照附图所做的详细描述,本发明更多的特征,以及由此得到的优点将清晰可见。所述附图中:
图1是根据本发明一个实施方案的涂覆碳化物丝锥的透视图;
图2是图1丝锥切削刃处的横截面视图,其展示出一个单层的耐磨涂层;
图3是图1丝锥切削刃处的横截面视图,其展示出一个由多个或交替的耐磨层构成的涂层;
图4是图1丝锥切削刃处的横截面视图,其展示出一个单层耐磨内涂层和一个单层减摩外涂层;
图5是图1丝锥切削刃处的横截面视图,其展示出一个由多个或交替的耐磨涂层构成的内涂层和一个单层减摩外涂层;
图6是图1丝锥切削刃处的横截面视图,其展示出一个单层耐磨内涂层和多个或交替的减摩外涂层;
图7是图1丝锥切削刃处的横截面视图,其展示出一个由多个或交替的耐磨涂层构成的内层和多个或交替的减摩外涂层;以及
图8是图1丝锥切削刃处的横截面视图,其展示出基体、强化结合的金属层、耐磨内层、强化结合的金属层以及减摩外层。
优选实施方案描述
现在参照图1,对一般标记为10的根据本发明一个实施方案的精密的烧结碳化物攻丝丝锥进行说明。丝锥10由通常称作基体16(图2-8)的烧结碳化钨圆柱状坯体制造而成。该坯体的直径使其尺寸大于丝锥10的最终尺寸,并且在表面42和44进行定尺切割。
基体16的典型材料是采用钴粘结的碳化钨。钴的量可以为约12-16重量%。此外,可以添加少量过渡金属碳化物以限制晶粒长大,而且,基体16还可以含有低含量的可能在工艺期间引入的杂质。
加工基体16的第一步是采用例如在中心进行外圆纵向磨削(cylindrical traverse grinding)方法或者无中心切入磨(centerless infeed grinding)法将坯体磨削至精确圆柱公差。在该步骤期间,柄表面46被磨削至指定尺寸,并且形成攻丝部分31的主直径。此外,在该加工期间,或者作为一个附加工艺的结果,产生具有圆柱表面52的任选颈部49,并且在圆柱状柄46与颈部49之间存在斜面48。此外,任选斜面24可以通过外圆磨削加工而成。柄46的直径约等于螺纹名义直径。
应该意识到:可以对柄作其他选择。例如,在大直径丝锥上,柄可以比螺纹名义直径小;而对于小直径丝锥,柄直径可以比螺纹名义直径大。此外,为了在使用期间对其进行驱动,丝锥在其柄最端部可以为方形。
在下一个步骤,磨削出一个或多个凹槽50,以便与斜面30结合,提供切削刃,并且提供排除使用丝锥时形成的碎屑的途径。如图1所示,凹槽50呈笔直状,并且其取向一般与丝锥10的轴平行。应该认识到:凹槽可以有其它取向。例如,在丝锥进入部分,可以在与丝锥10的纵轴呈5-20角的方向磨削短凹槽,以便在使用期间迫使碎屑处于丝锥运动的前方。或者,凹槽50可以为螺旋型,根据丝锥使用期间是否期望将碎屑排出孔或将碎屑推至丝锥运动的前方,来选择螺旋的旋向。
接下来的步骤中,在一个螺旋状物上磨削攻丝体部分31,形成V型螺纹侧面表面,以及内径和外径。随后,通过磨削形成切削斜面30的形状。V型螺纹侧面表面和外径复制出攻丝期间产生的内部螺纹。切削斜面30逐步变细,以便能够进入所攻丝的孔中。
前面介绍的某些基本步骤给出了获得图1中丝锥10的工艺的特点。但是,应该意识到:所述工艺可以采取任何数目的适合的步骤。采用上述基本步骤是为了便于描述。因此,本发明的范围不限于上面给出的具体工艺步骤。
下一个步骤是在丝锥10上涂覆包含金属氮化物、碳化物、碳氮化物、硼化物和/或氧化物的耐磨层54,其中,所述金属选自于一种或多种下述元素:铝、硅和周期表中的IVa,Va,和VIa族过渡金属。
耐磨层54可以作为单一层,或者多层或交替层沉积在基体16上。图2示出的是涂覆在丝锥10的所有关键区包括螺纹31、斜面30和凹槽50的基体16上、由上述金属氮化物、碳化物、碳氮化物、硼化物和/或氧化物构成的耐磨单层54。应该认识到:涂层涂覆在除柄46之外的丝锥10的任何其他区域,柄46被遮蔽起来以避免被涂覆。图2所示的单层耐磨涂层54的一个实例是碳氮化钛。
图3示出的是上述金属氮化物、碳化物、碳氮化物、硼化物和/或氧化物作为多层或交替层54a-d已涂覆其上的基体16。图3所示的多层或交替层54a-d耐磨涂层的一个实例是氮化钛和氮化钛铝。
为了降低摩擦,可以在单层54上沉积任选顶部外层56。该外层56可以由二硫化钼、二硫化钼和过渡金属或者它们的任意组合组成,或者作为单层通过共沉积形成,或者以包括碳、碳和过渡金属碳化物、碳和过渡金属、碳氮化物或者它们的任意组合的层的多层或交替层形式沉积。
图4示出的是在由上述金属氮化物、碳化物、碳氮化物、硼化物和/或氧化物构成的先前已沉积的耐磨单层54上涂覆的作为单个单层的任选减摩外涂层56。图5示出的是在先前已沉积由上述金属氮化物、碳化物、碳氮化物、硼化物和/或氧化物构成的耐磨多层或交替层54a-d上涂覆的作为单层的任选减摩外涂层56。当减摩外涂层56作为单个单层沉积时,减摩涂层56可以由二硫化钼;共沉积的二硫化钼和过渡金属;共沉积的碳和过渡金属碳化物;共沉积的碳和过渡金属;碳;和碳氮化物构成。图4和5中示出的减摩外涂层56的一个实例是共沉积的二硫化钼和钛。
图6示出的是在先前已沉积由上述金属氮化物、碳化物、碳氮化物、硼化物和/或氧化物构成的单层54上涂覆的任选的多层减摩外涂层56a-d。图7示出的是在先前已沉积由上述金属氮化物、碳化物、碳氮化物、硼化物和/或氧化物构成的多层54a-d上涂覆的任选的多层减摩外涂层56a-d。当多层或交替层减摩外涂层56a-d作为多层涂覆时,可以作为由二硫化钼和过渡金属、碳和过渡金属碳化物;以及碳和过渡金属构成的交替层涂覆。一个这类减摩多层或交替层56a-d的实例是碳与铬的交替层。
上述金属氮化物、碳化物、碳氮化物、硼化物和/或氧化物,或者由二硫化钼;二硫化钼和过渡金属;碳;碳和过渡金属碳化物;碳和过渡金属;以及碳氮化物构成的上述减摩外涂层均可以采用目前众所周知的方法进行涂覆,所述方法例如是物理气相沉积(PVD)技术,任何高离子密度方法,比如离子镀、磁控溅射、电弧蒸发等,或者使用能够获得令人满意的CVD层的各种CVD方法的化学气相沉积(CVD)技术。
应该认识到:单层54和/或多层或交替层54a-d可以具有变化的或者梯度化学组成。例如,涂层一开始为氮化钛,之后可以引入碳,这样,在最靠近外层56的表面处涂层为碳氮化钛。此外,应该意识到:本发明不受多层或交替层54a-d,56a-d的数目的限制,可以采用任意多个多层或交替层实施本发明。例如,耐磨层54可以包括氮化钛和氮化钛铝两个交替层54a,54b。在另一个实例中,减摩外涂层56可以包括碳与铬两个交替层56a,56b。
为了提高耐磨层54或54a-d与基体16的结合性能,可以首先在基体16上涂覆金属层58,如图8所示。类似地,可以在所述任选的减摩层56或56a-d与耐磨内层54或54a-d之间涂覆金属层60。用于涂层58,60的提高结合性能的金属选自于一种或多种下述元素:铝、硅和周期表中的IVa,Va,和VIa族过渡金属。
实施了证实本发明涂覆碳化物丝锥切削有效性的试验。在一个试验中,通过以91米/分钟(300英尺/分钟)的速度对33HRC AISI 4340钢进行攻丝,测试了M12×1.25mm螺距的涂覆碳化物丝锥。该碳化物涂覆丝锥由具有15%钴的碳化钨制造并且采用碳氮化钛涂覆。实验结果表明:所述碳化物丝锥加工出1686个螺纹孔而磨损程度极小,相比之下,传统的涂覆TiN的HSS丝锥在91米/分钟(300英尺/分钟)的同样速度下只能够产生158个孔。也已发现:只是在15米/分钟(50英尺/分钟)的较低速度下,传统的涂覆TiN的HSS丝锥才能够产生数目相当的孔。
在本发明的M12×1.25碳化物丝锥的另一个实验中,我们发现:本发明的丝锥在对JIS SCM440钢攻丝时可以在80米/分钟(262英尺/分钟)的速度下使用。目前,采用传统攻丝技术对SCM440钢攻丝时,推荐速度仅为14米/分钟(46英尺/分钟)。
在本文引入本文中引用的文件、专利和专利申请,作为参考。
尽管已结合各种实施方案对本发明进行了具体描述,但是,应该理解这只是为了说明而不是进行限定,应该认为附后的权利要求范围同当前技术的允许范围一样广泛。
Claims (11)
1.一种涂覆碳化物丝锥,由采用12-16wt%钴粘结的碳化钨构成的基体制造并且采用第一个耐磨层涂覆,且所述第一个耐磨层由氮化钛和氮化钛铝的交替层构成。
2.根据权利要求1的涂覆碳化物丝锥,其中,所述交替层具有变化的或梯度的化学组成。
3.根据权利要求1的涂覆碳化物丝锥,还包括涂覆在所述第一个耐磨层上的第二个用于减摩的外涂层。
4.根据权利要求3的涂覆碳化物丝锥,其中,所述外涂层包含二硫化钼;或者二硫化钼和过渡金属。
5.根据权利要求3的涂覆碳化物丝锥,其中,所述外涂层包含碳;或者碳和过渡金属碳化物。
6.根据权利要求3的涂覆碳化物丝锥,其中,所述外涂层包含碳和过渡金属。
7.根据权利要求3的涂覆碳化物丝锥,其中,所述外涂层包含碳氮化物。
8.根据权利要求3的涂覆碳化物丝锥,其中,所述外涂层共沉积而成,形成一个单一层,或者以多层或交替层形式沉积而成。
9.根据权利要求1的涂覆碳化物丝锥,其中,所述基体还包含用于限制晶粒长大的过渡金属碳化物。
10.根据权利要求1的涂覆碳化物丝锥,还包括沉积在所述基体上的提高结合性能的涂层。
11.根据权利要求3的涂覆碳化物丝锥,还包括沉积在所述第一个耐磨层上的提高结合性能涂层。
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US10/375,299 US7147939B2 (en) | 2003-02-27 | 2003-02-27 | Coated carbide tap |
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PCT/US2004/004775 WO2004076171A1 (en) | 2003-02-27 | 2004-02-18 | Coated carbide tap |
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Also Published As
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WO2004076171A1 (en) | 2004-09-10 |
EP1597064A4 (en) | 2008-06-25 |
US20040170872A1 (en) | 2004-09-02 |
CN102581394B (zh) | 2015-06-17 |
JP2006519114A (ja) | 2006-08-24 |
EP1597064A1 (en) | 2005-11-23 |
CN102581394A (zh) | 2012-07-18 |
US7147939B2 (en) | 2006-12-12 |
CN1829599A (zh) | 2006-09-06 |
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